H6HK Series Installation Instructions Electric Heater Kits Installation in Standard and Variable Speed Indoor Air Handlers IMPORTANT: The instructions included with this heater kit are for installations in air handlers only. These instructions are primarily intended to assist qualifi ed individuals experienced in the proper installation of heating and/or air conditioning appliances. Some local codes require licensed installation/service personnel for this type of equipment. All installations must be in accordance with these instructions and with all applicable national and local codes and standards. Before beginning the installation, read these instructions thoroughly and follow all warnings and cautions in the instructions and on the unit. Improper installation, service, adjustment, or maintenance can cause explosion, fi re, electrical shock, or other conditions which may result in personal injury or property damage. Unless otherwise noted in these instructions, only factory authorized kits or accessories may be used when modifying this product. INTRODUCTION The H6HK Series of electric heater kits are approved for fi eld installation in B5 air handlers and variable speed air handlers. All sizes are available with factory-provided circuit-breakers for short circuit protection and to provide a disconnecting means. Also available are 5, 8, and 10 kw electric heater kits without circuit-breakers. Refer to the National Electric Code (ANSI/NFPA 70) and applicable local codes for over-current protection and disconnect requirements. Note: The 20, 25, and 30 kw electric heater kits are Not Approved for installation in A-cabinet air handlers. Reference Table 2 for all Heater Kit applications. Note: These instructions are written assuming the air handler is in the upfl ow position (with the outlet facing up). For horizontal and downflow applications, it is recommended that the electric heater kit be installed prior to installation of the air handler.
WARNING: To avoid the risk of electric shock, personal injury, or death, disconnect all electrical power to the unit before performing any maintenance or service. The unit may have more than one electrical power supply. AIR HANDLER ELECTRICAL SUPPLY All wiring must be in compliance with the National Electric Code and applicable local codes. If the air handler was previously installed without electric heat the existing supply wiring may not be sufficient to carry the increased load. If installing electric heat in the B5 air handler the supply wiring can be aluminum or copper since the circuit breakers and terminal blocks supplied are approved for either wire type. Be sure to follow all of the rating information on the circuit breaker or terminal block and ensure that the supply wiring is sized according to the current NEC codes and any other state or local codes. See the rating label or Table 1 for minimum circuit ampacities and maximum overcurrent protection. Installation into Air Handler, All Heater Kits Insert the element assembly into the opening in the air handler control box being careful not to damage the element wire or the ceramic element supports. Heating element alignment rod(s) will slide into alignment holes in the back of the air handler element box. Secure the element assembly to the back of the air handler control box with the screws removed when removing the element close-off plate(s). For 25 kw and 30 kw Heater Kits, attach the Auxiliary circuit board bracket to the lower right side of the installed Heater Kit Assembly with two screws that were removed from the element close-off plate(s). Snap on the Auxiliary circuit board as shown below. Note: on some units a shipping bracket must be removed before installing the circuit breaker bracket. All electric heater kits of 10 kw or less are supplied from the factory confi gured for use with a single supply circuit. Electric heater kits greater than 10 kw are supplied from the factory confi gured for use with two supply circuits. See the ratings label or Table 1 for individual circuit ampacities and over-current protection ratings. If a single supply is desired, accessory kit #913874 is required to convert to single circuit connection. INSTALLATION Remove the upper access door from the air handler. Remove the circuit breaker bracket and cover package from the heater kit. Remove the top-most element Close-off Plate from the back of the air handler control box. For two-tiered electric heater kits remove both Close-off Plates. For three-tiered electric heater kits remove all three Close-off Plates. Figure 1. Sample Installation. Shown without access door. Install the circuit-breaker bracket (See Figure 1). Connect the 2-Pin Power plug from the element assembly into the unit's 2-Pin power plug. Connect the 7-Pin Harness from the element assembly to the unit's circuit board. For 25 kw and 30 kw Heater Kits, also attach the 4-Pin and 3-Pin Harnesses to the Auxiliary circuit board. 2
Standard Air Handler (A & B size) Variable Speed & Std Air Handler (C size) Model Number H6HK- Voltage KW Min. Circuit Max. Over- Min. Circuit Max. Over- Ampacity Current Protection Ampacity Current Protection Circuit Circuit Circuit Single Circuit Circuit Circuit Single Circuit Circuit Circuit Single Circuit Circuit Circuit Single A B C Circuit A B C Circuit A B C Circuit A B C Circuit 005H-XX 240 4.8 - - - 30 - - - 30 - - - 34 - - - 40 008H-XX 240 7.5 - - - 45 - - - 50 - - - 48 - - - 50 010H-XX 240 9.6 - - - 55 - - - 60 - - - 59 - - - 60 015H-XX 240 14.4 55 25-80 60 30-90 59 25-83 60 30-90 020H-XX 240 19.2 55 50-105 60 60-125 59 50-109 60 60-125 025H-XX 240 24.0 - - - - - - - - 59 50 25 134 60 60 30 150 030H-XX 240 28.8 - - - - - - - - 59 50 50 159 60 60 60 175 005H-XX 208 3.6 - - - 27 - - - 30 - - - 30 - - - 40 008H-XX 208 5.6 - - - 39 - - - 40 - - - 42 - - - 50 010H-XX 208 7.2 - - - 48 - - - 50 - - - 52 - - - 60 015H-XX 208 10.8 48 21-70 50 25-80 52 22-73 60 25-80 020H-XX 208 14.4 48 43-92 50 50-100 52 43-95 60 50-100 025H-XX 208 18.0 - - - - - - - - 52 43 22 117 60 50 25 125 030H-XX 208 21.6 - - - - - - - - 52 43 43 138 60 50 50 150 009Q-XX 240 9.0 - - - 32 - - - 40 - - - 36 - - - 40 015Q-XX 240 14.4 - - - 48 - - - 50 - - - 52 - - - 60 009Q-XX 208 6.8 - - - 29 - - - 30 - - - 32 - - - 40 015Q-XX 208 10.8 - - - 43 - - - 50 - - - 46 - - - 50 Table 1. Electrical Ratings A wiring diagram and a ratings label are supplied with the electric heater kit. Attach the wiring diagram to the Blower Housing. When installing the electric heater kit into a standard air handler, attach the rating label (included with the electric heater kit) on the air handler unit data label (located on the lower access door) over the electrical data section. When installing the electric heater kit into a variable speed air handler the rating label supplied with the kit will not be used. Check the appropriate block on the air handler additional ratings label located on the lower access door. WARNING: To avoid risk of electric shock, personal injury, or death, disconnect electrical power to the unit before performing any maintenance or service. The unit may have more than one electric power supply. Figure 2. Circuit Breaker Brackets. Shown with Line Cover Removed and Terminal Block Installed. Electric Heater Kits without Circuit Breakers Attach the supplied power terminal block to the circuit-breaker bracket with the supplied screws as shown in Figure 2. Using the 1/4" terminals, connect the red supply wire(s) from the element assembly to one pole of the terminal block and connect the black wires to the other pole. 3
Figure 3. Line Cover Figure 5. Installation of Circuit Breakers is required by code in order to protect installers from the line/supply wiring. The line cover should be installed as shown in Figure 4. 5, 8, and 10 kw electric heater kits supplied with a circuit breaker. Snap the circuit breaker on to the circuit breaker bracket as shown in Figure 5. The orientation of the circuit breaker must be as shown. (Side with 1/4" terminals to the right). Figure 4. Line Cover Installed Electric Heater Kits with Circuit Breakers NOTE : Circuit breakers supplied with the H6HK electric heater kits are for shortcircuit protection of the internal wiring and to serve as a unit disconnect. Circuit breakers supplied with the H6HK electric heater kits do not provide over-current protection of the supply wiring. Over-current protection of the supply wiring must be provided at the distribution panel and sized as shown in Table 1 or on the unit data label and per the NEC and applicable local codes. In some cases the over-current protection specifi ed in Table 1 or on the unit data label is less than the 60 amp rating of the circuit breakers used in the H6HK electric heater kits. This is because the function of the over-current protection required at the distribution panel (field supplied) and the function of the circuit breakers in the H6HK electric heater kit is different. Heater Kits with circuit breakers are supplied with a line cover shown in Figure 3. The line cover Remove the lower circuit breaker knockout from the air handler upper access door. 15, 20, 25, and 30 kw electric heater kits supplied with circuit breakers. Snap the circuit breakers on to the circuit breaker bracket as shown in Figure 5. The orientation of the circuit breakers must be as shown in Figure 1. (Side with 1/4" terminals to the right). The heavy red and black supply leads are bundled by circuit with wire ties at the factory. The bundle coming from the top element tier is circuit A (note: the element assembly is right-side-up when the limits are on the right side). The bundle coming from the second element tier is circuit B. The bundle coming from the bottom element tier is circuit "C". Remove all necessary circuit breaker knockouts in the air handler upper access door. 3-Phase 9 and 15 kw electric heater kits supplied with a circuit breaker. 4
Snap the 3-pole circuit breaker on to the circuit breaker bracket as shown in Figure 5. The orientation of the circuit breaker must be as shown. (Side with 1/4" terminals to the right). Remove all circuit breaker knockouts in the air handler upper access door. STAGING All Single-phase heater kits are internally staged using the B5 Air Handler Circuit Board logic. Reference B5 Air Handler Installation Instructions for "slow" or "fast" staging options. All Three-phase heater kits are not equipped for internal staging. WIRING All wiring must comply with the current revision of the National Electric Code and must be sized for the minimum ampacities as listed on the unit data label or in Table 1. If a single circuit adaptor kit is used it may need to be re-confi gured for some applications. Remove the single circuit adaptor kit cover and verify that the lugs are confi gured correctly for the application. If the lugs are not confi gured for the application, reference the instructions included with the kit and modify the configuration. Install the single circuit adaptor kit (if used) in the line side ( on end) of the circuit breakers. Tighten the lugs securely (45 in-lbs recommended). Connect the supply wiring to the circuit breaker(s), single circuit adaptor kit, or terminal block. Tighten the lugs securely. When using multiple supply circuits verify that the supply sized for circuit A is connected to the circuit breaker that is connected to the top element assembly. Install metal circuit breaker line cover on the left side of the circuit breaker to cover the supply wires. Note; on 3-phase heater kit installations after the air handler door has been attached to the unit, install the circuit breaker close-off to the opening in the door just above the circuit breaker. MOTOR SPEED SELECTION Standard Air Handlers The blower speed is preset at the factory for operation at the same speed for heating and cooling, by using the blower motor jumpering terminal on the blower motor and connecting it to the desired speed with both the red and black wires connected to the jumpering terminal. For optimum system performance and comfort, it may be necessary to change the factory set speed. To change the blower speed, disconnect all electrical power to the unit and remove the upper door. Remove the black and red wires from the blower motor jumpering terminal. Discard the blower motor jumpering terminal. Connect the heating speed wire (red) and the cooling speed wire (black) to the desired blower speed marked on the terminal block of the blower motor. On standard 3 speed motors terminal 4 = Hi speed, terminal 5 = Med speed and terminal 6 = Low speed. Standard C cabinet units are equipped with 5 selectable blower speeds. Terminal 1=Low speed, terminal 2=Medium Low speed, terminal 3=Medium speed, terminal 4=Medium Hi speed and terminal 5=Hi speed. IMPORTANT: After making any changes to the blower speed setting be sure to bundle and insulate any unused blower motor leads so that they will not come in contact with the air handler cabinet or non-insulated live parts. High speed operation may be required when using a 20, 25, and 30 kw electric heater kit in a downflow application. (See Clearance section.) Replace the upper door and secure it to the unit. Restore power to the unit. Variable Speed Air Handlers The minimum electric heat airflow is selected by setting switches on the air handler circuit board. Selecting the minimum electric heat airfl ow sets the minimum air flow that will be produced whenever electric heater kits are energized. When the electric heater kits are energized along with a heat pump the airfl ow may be higher depending on the basic cooling/heat-pump airfl ow setting. Reference the variable speed air handler installation instructions for further details. 5
CLEARANCE Standard Air Handlers All electric heater kits less than 20 kw are approved for use in air handler installations with zero-clearance to combustibles at any blower speed. For horizontal and upflow configuration, air handlers equipped with 20, 25, and 30 kw electric heater kits are approved for installation with zero clearance to combustibles at any blower speed. When using a 20, 25 kw electric heat kit in a downflow installation, the blower MUST be set for high speed for both heating and cooling. Variable Speed Air Handlers All installations of H6HK electric heater kits in variable speed air handlers are approved for zero-clearance to combustibles when the minimum electric heat airflow is set as directed in these instructions. Minimum Required Blower Model Applicable Cabinet Size Heating Speed H6HK A B C Up-Flow Horizontal Down-Flow 005H X X X LOW LOW LOW 008H X X X LOW LOW LOW 010H X X X LOW LOW LOW 015H (1)* X X X LOW LOW MED 020H X X LOW LOW HIGH 025H X X MED MED HIGH 030H X MED MED N/A 009Q X X LOW LOW LOW 015Q X X LOW LOW MED (1) Only on *30 (2.5 Ton) model air handlers Table 2. Blower Heating Speed MODEL IDENTIFICATION H6 H K - 020 H - 2 1 Product Type H - Heater Generation 6 - Sixth Series Product Identifier HK - Heater Kit Staging Circuit Breakers Electrical Code H : 240-1 - 60 Q : 208/240-3 - 60 Primary Capacity 005-5kw 009-9kw 015-15kw 025-25kw 008-8kw 010-10kw 020-20kw 030-30kw 6
REPLACEMENT PARTS LIST H6HK Heater Kits No. Component Description Model H6HK 005H-01 005H-11 008H-01 008H-11 009Q-11 010H-01 010H-11 015H-21 015Q-11 020H-21 025H-31 030H-31 1 Set of Wires 288351R 288351R 288361R 288361R 291531R 288361R 288361R 288371R 291531R 288381R 289011R 288391R 2 Harness, 634664 634664 634665 634665 634665 634665 634665 634666 634665 634667 634668 634668 Element Assy 491214R 491214R 491226R 491226R 491216R 491225R 491225R 491214R 491214R 491225R 491214R 491225R 3 Element Assy 491227R 491225R 491225R 491225R 4 Relay 622210 622210 622210 622210 622210 622210 622210 622210 622210 622210 622210 622210 Limit Switch 626487 626487 626458 626458 626458 626458 626458 626458 626458 626458 626458 626458 5 Limit Switch 626487 626487 6 Terminal Block 631762 631762 631762 7 Line Cover 257442 257442 257442 257442 257442 257442 257442 257442 257442 257442 257443 257443 8 Bracket, Circuit Breaker 284861 284861 284861 284861 284861 284861 284861 284861 284861 284861 284862 284862 9 Circuit Breaker 632249 632249 632225 632249 632249 632225 632249 632249 632249 10 Harness, 2 Pin Power 288861R 288861R 288861R 288861R 288861R 288861R 288861R 288861R 288861R 288861R 11 Harness, 3 Pin 634670 634671 12 Bracket, Circuit Board 289841 289841 13 Circuit Board 624664 624664 14 Contactor 621888 621888 15 Relay Bracket 288621 288621 288621 288621 288621 288621 288621 288621 288621 288621 288621 288621 16 Cover Plate, Limit hole 292211 292211 7
BLUE 1 2 3 4 5 6 7 1) If any of the original wire supplied with this unit must be replaced, it must be replaced with wiring material of the same gauge size and temperature rating. 2) The installation of this heater kit may require a change in the blower speed tap connection. See Installation Instructions for details. 3) Use copper conductors with a minimum temperature rating of 60 C for supply connections. TERMINAL BLOCK (for select models only) BREAKER (Circuit breaker models only) Legend 710560A Figure 4. Typical System Wiring Diagram H6HK, 5 kw 1-stage with circuit breaker 1 2 3 4 5 6 7 1) If any of the original wire supplied with this unit must be replaced, it must be replaced with wiring material of the same gauge size and temperature rating. 2) The installation of this heater kit may require a change in the blower speed tap connection. See Installation Instructions for details. 3) Use copper conductors with a minimum temperature rating of 60 C for supply connections. Legend TERMINAL BLOCK (for select models only) BREAKER 710561A Figure 5. Typical System Wiring Diagram H6HK, 8/10 kw 1-stage with circuit breaker 8
1 2 3 4 5 6 7 BREAKERS SUPPLY VOLTAGE GROUND Figure 6. Typical System Wiring Diagram 15 kw 1-stage with circuit breakers BROWN BLUE BLUE 1) If any of the original wire supplied with this unit must be replaced, it must be replaced with wiring material of the same gauge size and temperature rating. 2) The installation of this heater kit may require a change in the blower speed tap connection. See Installation Instructions for details. 3) Use copper conductors with a minimum temperature rating of 60 C for supply connections. Legend 710563A BREAKERS 1 2 3 4 5 6 7 SUPPLY VOLTAGE GROUND 1) If any of the original wire supplied with this unit must be replaced, it must be replaced with wiring material of the same gauge size and temperature rating. 2) The installation of this heater kit may require a change in the blower speed tap connection. See Installation Instructions for details. 3) Use copper conductors with a minimum temperature rating of 60 C for supply connections. Legend 710564A Figure 7. Typical System Wiring Diagram 20 kw 1-stage with circuit breakers 9
1 2 3 4 5 6 7 1 2 3 4 1 2 3 BREAKERS SUPPLY VOLTAGE Figure 8. Typical System Wiring Diagram 25 kw 1-stage with circuit breakers GROUND BLUE BROWN WHITE BROWN 1) If any of the original wire supplied with this unit must be replaced, it must be replaced with wiring material of the same gauge size and temperature rating. 2) The installation of this heater kit may require a change in the blower speed tap connection. See Installation Instructions for details. 3) Use copper conductors with a minimum temperature rating of 60 C for supply connections. Legend 710565A 10
Y 1 2 3 4 5 6 7 1 2 3 4 1 2 3 BREAKERS SUPPLY VOLTAGE Figure 9. Typical System Wiring Diagram 30 kw 1-stage with circuit breaker GROUND BLUE BROWN WHITE BROWN 1) If any of the original wire supplied with this unit must be replaced, it must be replaced with wiring material of the same gauge size and temperature rating. 2) The installation of this heater kit may require a change in the blower speed tap connection. See Installation Instructions for details. 3) Use copper conductors with a minimum temperature rating of 60 C for supply connections. Legend VIOLET 710566A 11
Legend TRANSFORMER 1) The blower motor speed tap connection may not be as shown. See the Installation Instructions. 2) Disconnect all power before servicing. 3) Transformer may have a dual voltage primary tap. Match the tap position with the supply voltage used. 4) If the Internal wiring is replaced, use only 105 C copper wire of the same gauge. 1 2 2 3 L1 L1 3 L2 L2 L3 L3 CONTACTOR WHITE 24V COM 1 NO From indoor air handler circuit board From indoor air handler circuit board 1 HEATER KIT PLUG 2 3 4 5 6 7 To indoor air handler circuit board BROWN PLUG GROUND SUPPLY VOLTAGE BREAKERS 7105670 Figure 10. Typical System Wiring Diagram 9kw and 15kw 3-phase electric heater kit INSTALLER: PLEASE LEAVE THESE INSTALLATION INSTRUCTIONS WITH THE HOMEOWNER 708514% 708514B 708514B (Replaces 708514A) Specifi cations and illustrations subject to change without notice and without incurring obligations. Printed in U.S.A. (09/06)